MPI Technologies FCX User's Manual
Contents
1. building Termination of a il flue vin UA ppl least 12 Hae 3 aboveXhe AIr In Option Straight Horizontal Flue Kit itso Ipatjon ef the sys Mey inches 40cm a Angled Balanced Flue Configuration Option Angled Horizontal Flue Kit Q INSTALLATION Typical installation examples cont Options 190 deg concentric elbow Concentric extensions 1 concentric vertical termi 1 sleeve tile 1 roof SR Y CS max L L1 1 64 ft 0 5m L2 1 64 ft 0 5m im lt 16 4 ft 5m L3 3 28 ft 1m lt 16 4 ft 5m Concentric vertical terminal 1 sleeve tile roof flange 1roof plate INSTALLATION Typical installation examples cont 90 elbow 90 elbow ie elbow 7 jm elbow 1 from above from rear Hes m rear boiler lt Options 145 deg con2. Note The condensate will not likely require any spe cific water treatment because of condensate dilution by normal wastewater use If however local regula tions require wastewater to have a neutral pH a condensate treatment tank can be installed between the trap and the sewer Q INSTALLATION 5 WATER CIRCUIT CONNECTIONS Water circuit connections are made in the back of the unit utilizing the four 1 male pipe thread cou plings provided Model FCX can be connected to va rious comfort heating water systems as well as to a domestic hot water heating system if desired obser ving that Water circulating pumps provided in the va rious circuits must be large enough for each circuit including the pressure drop of the boiler condenser in the unit For optimum sound level and power consumption set the circulator to the speed that is appropriate for the installation flow rate and pressure drop Various typical water circuits are illustrated below Connection to a single heating circuit Ss Isolation valves may be used in the various cir cuits to facilitate boiler maintenance without having to completely drain each circuit NE VER place an isolation valve between a pres sure relief device and a water tank An expans
3. 2 DZO SOCAAMZMOP TABLE OF CONTENTS 17 SS INTRODUCTION 3 t1 PRODUCT DESCRIPTION tacite rente rte 3 2 DESIGNATION OF COMPONENTS cere eens eters nennen nne 4 3c BOILER OPERA HON niet ht tien tie eter tlt e M t t ae ep v e doa 5 4 PRODUCT STANDARD 5 6 5 DIAMETER OF PIPE 6 Il INSTALLATION Pon 7 1 gt OPENING THE UNIT iier rete tede tete eaaa ee be de ee e ren dca Eve ur Eee ee 7 2 EOGATION OF TEE UNIT bt edt f Ged Ee 7 3 FLUE CONNECTIONS AND 2 nens 8 4 CONDENSATE DRAIN 13 5 WATER CIRCUIT 8 14 6 FUEL OIL SUPPLY CONNECTION So 15 7 ELECTRICAL 5 16 Ill gt START UP AND OPERATION eben e a E a 1 PRE START FINAL SYSTEM 2 START UP AND 2 2 42 22255 3 ADJUSTING THE OIL BURNER 4 CHECKING THE SAFETY DEVICES IV MAINTENANCE A pue ctm CLEANING THE BOILER 5 CLEANI
4. 274 circuit heating output Rc2 274 circuit heating retum Sd Heating output sensor C3 Domestic hot water production circuit Domestic hot water pump B Domestic hot water production system Ss Domestic hot water sensor 6 FUEL OIL SUPPLY CONNECTIONS Flexible fuel oil supply and return lines are supplied with the unit and connected to the oil burner Lines are terminated with 3 8 inch reverse flare fittings for connection of the supply and return lines from the fuel oil tank When connecting the lines a 10 micron Gerber oil filter must be installed in the oil supply line to minimize burner contamination Q INSTALLATION 7 ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD DISCONNECT THE POWER SUPPLY BEFORE ATTEMPTING ELECTRICAL INSTALLATION OF THE UNIT Electrical power and control connections are made to pigtail leads that exit through a hole in the right rear of the unit facing the front of the unit The power connections must be made in a Listed junction box that is not provided with the unit All wi ring should conform to the National Electrical Code and any applicable local codes and standards To minimize the likelihood of a heating system shut down caused by an unrelated electrical circuit fault the unit and any related electrical components should be connected to a separate branch circuit specifically dedicated for that purpos
5. Product Rating Rated Output BTUH 76 000 Rated Input BTUH 81 250 Combustion Chamber Length Inches 8 98 Combustion Chamber Diameter Inches 11 5 Combustion Chamber Volume Cu Inches 915 Combustion Prod Circuit Volume Cu Inches 3051 Flue Pressure Drop Inches 2 0 10 Maximum Heating Service Pressure Psig 43 5 Max Heating circuit water temperature Deg F Water Overheating Safety Thermostat Setting Deg Combustion Prod Overheating Safety Thermostat Setting D Heating Circuit Water Capacity ion Primary Water Flow Rate 60 80 deg d Y DU Water Pressure Drop at nomin lt gt 1 4 Power Absorbed thout V T 0 22 Pack f Lb 267 gs arg forl k ery k TAN 797 ts So rid 115 volts single phase 60 Hz A Auo t 3 0 Amps FLA Fuse Circuit Breaker Size 15 Amps 4 DIAMETER OF PIPE CONNECTIONS Connection Diameter Units Combustion Products 3 15 4 92 Inch Water Heating Supply Return 1 Inch Domestic Hot Water or Second Heating Circuit 1 Inch Condensate Drain 1 1 2 Inch Heating Water Drain Ve Inch Air Bleed 3 8 Inch Safety pressure relief valve 3 4 inch Q ll INSTALLATION 1 OPENING THE UNIT To open Model FCX to access for installation and or service follow these steps Remove the control panel escutcheon molding 2 by grasping it on both sides and pulling it outward towards you
6. Reference Number g mm B00 29727 3 125 Collars are essential to bear the weight of the verti cal extensions so that the boiler does not bear the weight Q INSTALLATION Typical installation examples All flue piping components must be assembled to The flue combustion air system piping may be either provides horizontal or vertical or a combination of both ob Application of liquid soap over the flue pipes to be serving the following joined will aid in assembly of the parts The maximum unrestricted horizontal or verti Typical installation examples appear in the illustra cal flue length shall not be more than 16 4 ft tion that follow 5 Straight Balanced Flue Configuration For each 90 degree elbow used in the flue sys tem subtract 3 3 ft 1m from the total allowa ble length For each 45 degree elbow used in the flue sys tem subtract 1 65 ft 0 5m from the total allo wable length Horizontal runs of the flue system must pitch down 3 4 inch per yard 2 cm per m of length towards the boiler to facilitate proper flue pro ducts condensate drainage Termination of a horizontal flue system shall not be less than 5 96 ft 1 8m above ground unless other provisions are made to minimize the likelihood of flue combustion air intake blockage Do not place the flue terminal less than 3 3 ft 1 m from a ventilation hole or opening in a
7. and up The escutcheon will come free of the attachment clips leaving the con trol panel exposed Remove the top cover of the unit A by lifting the cover at the front and rear to free the attachment clips and then simply lift the cover straight up and off Remove the front panel attachment screws P then pull the front panel J outward towards you at the top to free it from the attachment clips Lift the panel up to free it from the lower attachment pins and simply lift the panel off 2 LOCATION OF THE UNIT choice itable for installation on combustible floo pliance suitable for installation on co f infi lled in an enclosure hif pis Me e nd CM W fex en 055 tion or other means must be ig gt d so the enclosure temperature does from the cabinet Standard opt ion lt XJ 113 45 deg Model is free standing floor mounted ap course 6 ponents are suitable for inst SON a rance to combustiblezerateri amp l f These are eneralir sa Fi isf commen de i ads Considered eaa ante should be provided in CY we nit 1 to facilitate installation and VS of water electrical flue and con densaie drain connections and components Sufficient clearance over the top of the unit should be provided to allow the top to be remo ved f
8. it beco mes frequently necessary to add water to maintain pressure in the installation even though no lez have been discovered perform an expa check check to see that neither the installation nor the boi Pm f i 5 EXPANSION TANK PRE INFLATION PRFS GHEGK n SS eee Reduce the pressure in the heating ins I 4 totally opening the drain cock or the saf Xil thes wat e installation pressure gauge reading i 7 gt lt Check ti ansio Ak hd fhe 19 06 is gater present in l 8 E OI 1 P expansion tank lation pressure in line with the on The pressure must correspond to the static height of the installation H the height between the highest point of the installation and the expansion tank as expressed in bars where 10 meters in height 1 bar Adjust the filling pressure of the installation to a value greater than 3 psig 0 2 bar above the Dilated water volume Water inlet Membrane Max vessel Pressure rises as the Inflating valve volume air is compressed 6 COMBUSTION PRODUCT FLUE Examine the flue combustion air system for leaks and obstructions Leaks can generally be detected by the appearance of condensate stains on
9. the out side of the pipes Replace any damaged seals if ne cessary The flue combustion air pipe can be cleaned with running water if necessary providing that the water flow is not too great to be drained through the condensate drain system Leave the ex cess water in the condensate trap when cleaning is completed Q MAINTENANCE 7 CHANGING A THERMOSTAT OR THE THERMOMETER Replacement of the thermostats or the thermometer requires removal of the bulb from its location and the control from the control box The bulb for the Boiler Temperature Thermo meter is located on the first circuit heating out put tube Remove the bulb from the tube remove the thermometer mounting screws in the control box and remove the thermometer Replace the thermometer with another routing the bulb capillary the same way as the original replacing the bulb on the tube properly and as securely as possible The bulbs for the Boiler Temperature Control Thermostat and the Water Overheating Safety Thermostat are both located in pockets on the side of the boiler shell To change either remo ve the bulb from the pocket remove the ther mostat mounting screws in the control box and remove the thermostat Replace the thermos tat with another routing the bulb capillary the same way as the original replacing the bulb properly into the pocket as far as possible The bulb for the Combustion Product Overhea ting Thermostat is located i
10. NG THE CONDE AAT INTRODUCTION 1 PRODUCT DESCRIPTION Model oil fired boiler utilizes a sealed combus tion system that operates at a temperature at which the flue products will condense The flue products temperature is so low that the unit is suitable for use with PVC Polypropylene flue pipes which are offe red as standard options for installation Model FCX is approved for installation with zero clearance to combustible materials by Intertek Testing Services to the UL Standard for Oil Fired Storage Tank Water Heaters UL 732 Model FCX is completely assembled and provides standard parts as follows Anenameled steel cabinet with thick insulation A completely unitized thick shelled boiler with combustion chamber and a heat exchanger with a system of removable baffles stainless steel condenser with condensate drain A high efficiency low emission gun type oil burner with combustion air fan integral oil pump oil heater and primary control Acontrol panel assembly and all electrical con trols for operation of the boiler including a wa ter temperature thermometer in circuit 1 A manual water mixing valve that can be mo torized if desired A safety pressure relief valve Anexpansion tank A water circulating pump Complete internal water piping terminating in connections for two independent water hea ting circuits Complete internal air piping terminating i
11. RATION Circuit heating return or 2 21d circuit heating output 15 circuit heating output gh Atm drawn into the oil burner by the CY through the air intake hose connected to coaxial flue combustion air intake separator tube assembly Heated air from combustion of the oil burner cools as it passes through the boiler heat exchanger then the condenser Cooled flue pro ducts exit the unit through the center of the flue combustion air separator tube assembly Conden sate from the flue products is drained from the bot tom of the condenser into the condensate drain tube exiting the unit through the condensate drain system Water is circulated through the boiler heat exchan ger and condenser circuits where it is heated by the combustion of the oil burner Two independent wa ter heating circuits can be connected to the unit The first circuit passes through a three way mixing valve incorporated into the boiler This valve can either be used manually as supplied or driven by a regulator option The second circuit can supply another heating circuit and or a domestic hot water production system INTRODUCTION 3 PRODUCT STANDARD RATINGS Ratings for Model FCX are provided in the following table Performance Parameter Units
12. Y ISOLATION VALVES THAT MAY BE IN THE WATER SYSTEM SHUT OFF THE FUEL OIL SUPPLY IF SERVICING THE BURNER To gain access to the inside of the unit first remove the control panel cover escutcheon by grasping it on both sides and pulling directly outward towards you and up Remove any front panel screw s and remo ve the front panel by pulling the top out towards you and then lifting up to free the bottom from the moun ting pins Remove the top cover by simply pulling it up Remove the electrical terminal block protection 1 CLEANING THE BOILER SHELL Remove the screws from the cast iron boiler shell cover C Remove the flue outlet baffle D Remove the combustion baffles E Clean the inner walls of the boiler shel Reassemble all the parts the w theyly moved Y centering sc t ei oih lor than nocit pu CLEANING THE CONDENSER Remove the wing nut F from the condenser top cover G and remove the cover Remove the condenser access plug 7 Clean the condenser tubes H using a bottle brush or similar tool Observe that the combustion products can flow freely in the condenser tubes Replace the condenser access plug 7 and the top cover making sure that the seal I is properly positioned when replacing the cover Make sure that the seal 1 on the cover and the access plug is in good condition NOTE If after cleaning the condenser the tempe rature of t
13. centric elbow 190 deg concentric elbow Conceniric extensions 1 concentric 1sleev Stef 1 64 ft 0 5 m 3 28 ft 1m L L1 1 64 ft 0 5m L2 1 64 ft 0 5m 20ncentric extensions 3 45 deg concentric elbows 1 concentric vertical terminal 1 sleeve tile roof flange 1 roof plate lt 16 4 ft 5m L3 3 28 ft 1m 1 64 ft 0 5 m lt 16 4 ft 5m INSTALLATION Typical installation examples cont 90 elbow Da elbow view from above rear boiler Options 145 deg conceniric elbow a 290 deg concentric 2A 1 concentric amp ANN or QNA DRAIN CONNECTION Connection of the condensate drain piping system is to the back of the unit beneath the flue combus tion air separator tube assembly The condensate drain tube provided in the unit is 1 19 32 inches 40 mm O D to which the drain trap assembly supplied with the unit may be connected The condensate drain outlet connection on the trap is 1 19 32 in ches 40mm O D to which standard 1 1 2 inch tra de size schedule 40 PVC pipe can be connected to create the rest of the drain system The drain sys tem must pitch downward towards the sewer
14. e The control circuit connections can be in air splices made to pigtail leads provided Control circuit con nections are NEC Class 2 intended for connection to a typical room thermostat connection fo the installation 120V 60Hz earth LEGEND W White Blue Supply E Room Gy Grey 3 wires thermostat Br Brown 222 2 wires Bk Black O Orange R Red Dk G Dark green Lt G Light green cT icit i 1 gt ba j t Y gt Ce 7 j 4 5 ZW ue P Uy v OT Wir ter iten C TSE Overheat safety cutout quastat TRC Adjustable thermostat S TSF Flue gas safety cutout 2d ds 2 5 5 5 e EA 0 Lo V1 On light poe Jh V2 Burner safety shutdown MIA EH TRC TSE TSF light o C Bumer connector amp F Fuse 6 3 A sS R Relay x oi T Main transformer 120 2 cies 3 24 volts 5 zo g CC Circulating pump a 5 Notes Male connector Wieland 7 pts A Electric power leads factory provided at right rear of unit Permanently field splice 120 1 60 field provided power circuit leads in NEC junction box B Con
15. e Combustion Product Overheating Thermostat will result in an oil burner shutdown In either case the burner safety device light red on the control panel WILL REMAIN OFF and the green fault indicator light on the oil burner will REMAIN OFF The only way to tell if either device has opened is to check electrically or check the position of the reset button located under the screw cap over each device The Water Overheating Saf may open if the water t 230 deg F Water error this i ture Control e Didcement prod Product Overheating Safety u F Hepfostat may open if combustion products exceed 250 deg F 120C This may require adjustment of the oil burner to the proper firing rate or cleaning the boiler and or condenser After correcting any fault either thermostat must be manually reset by removing the screw cap on top and depressing the reset button SEPTEMBRE 2001 MPI P O BOX 3408 PRINCETON NEW JERSEY 08543 PHONE 800 524 1102 NJ 732 329 0900 FAX 732 329 0904
16. he flue gasses still exceeds 250 deg F 120C perform a boiler check plate by removing the screws in the rear and lifting Remove the control panel cover screws and remove the control panel cover The water can be bled from the unit by opening the drain cock on the base of the boiler shell using the tool supplied MAINTENANCE 3 BURNER MAINTENANCE Once adjusted properly regular maintenance of the oil burner is not generally required A routine exami nation of the burner should include examination of the burner fan and nozzle for dirt and the spark elec trodes for proper clearances Replace the fuel filter if necessary Cleaning and adjustment is always ap propriate during periodic inspection If burner firing rate adjustment is required follow instructions in Adjusting the Oil Burner ALWAYS CHECK FOR AND CORRECT ANY FUEL LEAKS 4 ADDITIONAL COMPONENT MAINTENANCE Check to see that the safety and regulation devices safety relief valve air bleed valve control box com ponents etc are operating properly Check also to see that the condensate drain siphon is clean If ne cessary remove the bottom of the siphon clean it replace it and then refill the siphon it with water Also ler have any water or fuel leaks leaks may produce a risk for safety and shorten the lifespan If
17. ion tank must be provided in the system to support an expansion of 6 96 of the total water capacity of all the circuits employed Safety pressure relief valve must be connected to the drain The water pressure gauge not supplied has to be fitted outside the unit T d W G 1 s X Vw A TT ji l phixer valve i i heating outlet circuit heating return a Boiler M Pressure gauge C1 Radiator circuit VM1 18 circuit mixer valve Dc1 1 circuit heating outlet Rc1 1 circuit heating return C3 Domestic hot water prepara tion circuit Domestic hot water pump B Domestic hot water production system Ss Domestic hot water sensor INSTALLATION Various typical water circuits cont Connection to a double heating circuit M Pressure gauge C1 Radiator circuit VM1 1 circuit mixer valve Dc1 1 circuit heating output Rc1 1 circuit heating return C1 C2 Underfloor heating circuit P2 274 heating circulator VM2 274 circuit mixer valve Dc2 274 circuit heating output Rc2 274 circuit heating return Sd Heating output sensor C2 circuit heating return C2 Underfloor heating circuit c2 P2 274 circuit heating circulator VM2 274 circuit mixer valve Dc2
18. method 1 Junction box 4 Oval Hole 2 Main Power Pigtail Leads 3 Unit Upper Back Panel 5 Control circuit Pigtail Leads START UP AND OPERATION 1 PRE START FINAL SYSTEM CHECK Before starting normal operation of the boiler and heating system perform the following final installa tion procedures Leak check the flue combustion air system to minimize the likelihood of leakage Leak check the entire water system repairing any leaks that may be found Fill the entire water system with water treated as desired for the application including anti 2 START UP AND OPERATION After completing the pre start final system checks the system can be started and run through start up checks and adjustments as required freeze solution if appropriate Open any shut off valves in the system Fill the condensate drain trap with water Leak check the fuel oil supply system and open any fuel shut off valves Re check the power and control circuit con nections THEN replace all cabinet access pa nels Energize the electrical power circuit to the unit P N XI X MJ f ek 1 Start Stop Switch 2 Summer Winter Switch Circulator control intside the boiler 3 Boiler Temperature Control Thermostat Boiler Temperature adjusted between 140 167 deg F 60 80C 4 Water Outlet Temperature Thermometer Circuit 1 5 6 7 8 Water O
19. n a connection to a coaxial flue combustion air in take system Standard options include Coaxial balanced flue syste connection to the flue produc 2 20 34 6 5 98 5 55 2 20 Front view Side view Rear view INTRODUCTION DESIGNATION OF COMPONENTS Front view Control Panel Control Panel Cover Safety Pressure Relief Valve Condenser Manual Mixing Valve Combustion Product Pressure Test Point Condenser Inspection Port Condensate Drain Drain Cock 10 Burner Air Inlet Pipe 11 Oil Burner 12 Safety Light and Reset Button 13 Sight Glass 14 Boiler Shell Rear view 15 Pockets for Water Overheating Safety and Ther mostat Bulbs Thermostat 16 Heating Output Sensor 17 Bleed 18 First Circuit Heating Output 19 Second Circuit heating output 20 Combustion Products Flue 21 First Circuit Heating Return 22 Second Circuit Heating Return 23 Well for Combustion Product Overheating Ther mostat Bulb 24 Protection Plate for Electrical Connections Box 25 Circulating pump 26 Expansion vessel INTRODUCTION 2 BOILER OPE
20. n a well provided in the condenser access plug inspection port Remove the combustion test point plug and washer from the inspection port to free the thermostat bulb and remove the bulb from the well Remove the thermostat mounting screws in the control box and remove the thermostat Replace the thermostat with another routing the bulb capillary the same way as the original and replacing the bulb properly into the well far as possible Replace the combustic point plug and washer the inspec securing the bulb in place d V OPERATING FAULTS During the course of seemingly normal operation there may be operating faults experienced in the system Some of the more common faults that may be encountered are BURNER FAULT SHUT DOWN The burner may shut down for any of several reasons at which point the burner safety device light red on the control pa nel will be ON and the there will be a green fault in dicator light lit on the oil burner This may be caused by a loss of fuel oil tank empty a fouled oil spray nozzle in the burner or perhaps a fouled or faulty flame sensor To attempt a re start after correcting any burner problem and the fuel supply is assured push the reset button on the burner The burner should re start after the preset time delay period ex pires OVERHEATING SAFETY THERMOSTAT SHUT DOWN Opening of either the Water Overheating Safety Thermostat or th
21. or service Sufficient clearance from the front of the unit should also be provided to facilitate adjust ments and service There is no need for additional clearance to either side of the unit since there is no access to the unit from either side Alternative access measures such as doors remo vable wall panels etc may be provided if desired Choosing the location should also take into account the total flue length to the outdoors See Flue Con nection and Routing In addition the choice of loca tion should consider the location of utilities such as electrical supply and sewer access for condensate drainage Location and routing of water lines is of Q INSTALLATION 3 FLUE CONNECTIONS AND ROUTING Connection of the coaxial flue combustion air piping system is in the back of the unit to the separator tube assembly The combustion products are ven ted from the boiler and condenser through the cen ter of the coaxial tube while the combustion air is supplied through the outside ring of the coaxial tube Since Model FCX is a condensing boiler flue pro ducts exiting the unit are relatively low temperature from 140 185 deg F 60 85 deg C and saturated with humidity Consequently an airtight corrosion resistant flue system must be provided Various standard option flue piping components and packages with which to create the flue system are available 0 98 m Straight Horizontal Flue Ki
22. red to achieve this maximum Check to determine that the 2 rate is from 12 13 percent and that there is no CO production Adjust the burner as required to achieve this operating cha racteristic Measure the temperature of the flue gas exiting the unit to determine that it does not exceed 250 de grees F 120 Combustion inspection can be carried out on the unit through the hole item N provided in the inspec tion port item 7 Be sure to replace the washer item and the test point screw item 6 properly after inspection the thermostat bulbs ioned in housings This is i to provide temperature sensing to facilitate burner shut down in the event of overheating Flame monitoring Check to make sure that the burner shuts down properly upon the deactivation or discon nection of the flame monitoring device or inter ruption of the flow of fuel Safety Pressure Relief valve Check the safety pressure relief valve in the heating circuit for proper operation IV MAINTENANCE It is recommend that the boiler and flue combustion air system be inspected and maintained annually by a qualified technician DISCONNECT ALL ELECTRICAL CIRCUITS BEFORE SERVICING THE UNIT CLOSE AN
23. t V72 28414 Reference Polypropylene PVC Concentric Terminal For Flat or Sloping Roof Vertical Reference Color Length O D 42 5 inches 3 15 inch 4 92 inch 0 28393 Tile 550mm 80mm 125mm 42 5 inches 3 15 inch 4 92 inch N40 28394 Black 1080mm 80mm 12 Useful length under sleeve 0 43 m ei m G AE a Reference Length O D 19 7 inches 3 15 inch 4 92 N40 28397 80mm 125mm 39 4 inches 3 15 inch 4 92inch N40 28398 4000 mm 80mm 125mm Useful length after assy 17 7 inches 0 45 m or 37 4 inches 0 95 m INSTALLATION Sleeve Tile with Adaptable Coupling Polypropylene Roof Plate Reference A90 12172 Reference Slope Covering Color type N40 12165 25 45 deg Tile Tile N40 12166 35 55 deg Tile Tile N40 12167 35 55deg 21816 Black Shingle Polypropylene PVC Concentric Elbow joint fitting 45 bend Reference gt 2 i a 2 m inch 4 92 inch IN 80mm 125mm P HN 3 15 inch 4 92 inch 0728796 90 80 125mm
24. trol circuit leads factory provided at right rear of the unit are 24 volt NEC class 2 for connection to a room thermostat INSTALLATION The hole in the right rear of the unit is a large flat oval Mount a Listed 2 x 4 inch HandiBox type junction box over the oval hole in such manner that part of the hole is left open When installing the junc tion box center the box vertically over the oval hole by using the center knockout the box Install a 1 2 inch trade size cable connector or insulating bushing in the knockout Secure the box with screws as required The open part of the oval hole can be either above or below the junction box depending upon the choi ce of wire routing The Class 2 control circuit leads will exit the open part of the hole UPPER LEFT REAR CORNER OF UNIT Facing rear of unit Route the factory supplied main power pigtail leads through the connector from inside the unit and secu re the connector clamp on the wires Install a second cable or conduit connector in ano ther knockout in the box for the power wiring system as required Connect the power wires and groun ding conductors to the pigtail leads in the box using Listed wire connectors and install a cover Route the factory supplied control circuit pigtail leads through the open part of the oval hole from in side the unit Connect the room thermostat wires to the control circuit pigtail leads using a suitable Class 2 wiring connection
25. verheating Safety Thermostat Burner Cutout Combustion Product Overheating Safety Ther mostat Boiler Shutdown Burner Safety Device Light Slot for Additional Control To start the boiler first make sure the room ther mostat is set at a high enough temperature to be closed so that any external water circulating pumps are running Turn the boiler On off switch to the ON position and set the Boiler Temperature Con trol thermostat to its maximum temperature setting Turn the Summer winter switch to WINTER This will start the internal circulating pump After the start time delay set on the oil burner for the oil heater has expired the burner will start Reduce the Boiler Temperature Control thermostat setting to make sure the boiler stops properly when controlled by that thermostat Increase the room temperature thermostat setting to make sure that the circulating pump s stop properly Q START UP AND OPERATION 3 ADJUSTING THE OIL BURNER While the oil burner is adjusted at the factory it is re commended that the operating characteristics of the burner be determined at start up and readjusted if necessary Run the unit long enough at the burner maximum firing rate to make sure the burner has reached a stable maximum operating temperature THEN check the burner and adjust as follows Check to determine that the smoke spot number does not exceed 0 5 with a Bacharach control Ad just the burner as requi
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